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Chevrolet Chevy Volt Electric Car Complete Workshop Service Repair Manual 2012 2013

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The Chevrolet Volt, first generation, produced for the 2012 and 2013 model years, represents a pioneering step in extended range electric vehicle (EREV) technology. This compact hatchback, designed with an aerodynamic philosophy, offers a unique selling proposition by combining electric-only driving for daily commutes with a gasoline engine to extend its operational range, effectively addressing range anxiety. Its innovative Voltec powertrain system, featuring a battery pack, electric motors, and a 1.4L Ecotec gasoline range extender, delivers a blend of efficiency and practicality. Known for its advanced electrification strategy and robust engineering, the Volt stands as a significant marker in the evolution of sustainable automotive solutions, making it a noteworthy vehicle for environmentally conscious drivers. This comprehensive workshop service repair manual provides extensive guidance for the Chevrolet Volt (PHEV1 chassis code) covering the 2012 and 2013 model years. It details maintenance procedures, diagnostic and troubleshooting steps, component removal and installation, and repair and overhaul instructions for all major systems, including the Electric Drive Unit (EDU), battery pack, range extender engine, chassis, suspension, and electrical systems. With over 2000 pages of information in English, this manual is an indispensable resource for owners, mechanics, and technicians seeking to maintain, diagnose, and repair the vehicle, ensuring its optimal performance and longevity. 🏷️ Basic Information Identification Make: Chevrolet Model: Volt Generation: First Generation Model Years Covered: 2012, 2013 Codes Chassis Code: PHEV1 👋 Introduction Market Position Vehicle Segment: Compact Hatchback / Extended Range Electric Vehicle (EREV) Unique Selling Proposition: Pioneering EREV technology, offering electric-only driving for daily commutes with a gasoline engine for extended range. Competitive Analysis Key Competitors: Nissan Leaf (BEV), Toyota Prius Plug-in Hybrid Key Features Electrification Strategy: Voltec powertrain system featuring a battery pack, electric motors, and a small gasoline engine as a generator. Design Philosophy: Aerodynamic design for improved efficiency, innovative powertrain integration. 📋 Manual Details Coverage Areas Coverage Scope: Complete Workshop Service Repair Manual Page Count Estimated Pages: Over 2000 (typical for comprehensive service manuals of this era) Manual Type Manual Category: Workshop Service Repair Manual Language Primary Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Electric Drive Unit (EDU), Extended Range Electric Motor, Regenerative Braking System, Battery Pack (Volt's Voltec System) Engine And Fuel: 1.4L Ecotec Gasoline Range Extender Engine (LLT), Fuel Tank and Lines, Exhaust System Transmission: Electric Drive Unit (eCVT-like functionality), Power Split Device Chassis And Suspension: Front and Rear Suspension, Steering System, Brakes (including regenerative braking integration) Electrical And Electronics: High Voltage Battery Management System (BMS), Powertrain Control Module (PCM), Body Control Module (BCM), Infotainment System, Lighting, Wiring Diagrams, Fuses, Relays Body And Interior: Body Panels, Doors, Seats, HVAC System, Interior Trim, Safety Restraints (Airbags) Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Tire Rotation, Battery Coolant Service Diagnostics And Troubleshooting: Fault Code Diagnosis, Symptom-Based Troubleshooting, Electrical System Diagnostics, Powertrain Diagnostics Repair And Overhaul: Engine Overhaul, Transmission (EDU) Repair, Suspension Component Replacement, Brake System Repair, Electrical Component Replacement, Battery Pack Servicing (limited to module replacement/testing where applicable) Component Removal And Installation: Detailed instructions for replacing virtually all major and minor components Technical Depth Depth Of Information: Comprehensive, covering everything from basic fluid checks to complex electrical system diagnostics and powertrain component rebuilds. Diagnostic Tools: Information on diagnostic trouble codes (DTCs), scan tool usage, and specialized procedures may be included. 📊 Manual Specifications File Format PDF Quality: Typically high-resolution scans of original factory manuals, optimized for readability and searchability. Print Quality Printable: Yes, the PDF format is generally designed to be printable. Binding Type Binding Method: N/A (Digital PDF) Paper Type Paper Quality: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Range Extender Engine (Gasoline) Engine Code: LLT (GM Ecotec family) Displacement: 1.4 Liters (1398 cc) Cylinders: 4 Configuration: Inline Valvetrain: DOHC, 16 Valves Performance Gasoline Engine Horsepower: 84 hp @ 4800 rpm Gasoline Engine Torque: 96 lb-ft @ 3800 rpm Electric Motor Peak Horsepower: 149 hp Electric Motor Peak Torque: 273 lb-ft Fuel System Fuel Type: Unleaded Gasoline Fuel Tank Capacity: 9.3 gallons (35.2 L) Ignition System: Electronic Ignition 🔧 Transmission Standard Transmission Type: Electric Drive Unit (EDU) with Power Split Device Optional Optional Transmission: N/A Features Drive Modes: Hold, Sport, Normal, Mountain Power Delivery: Electric motors drive the wheels directly; gasoline engine acts as a generator to recharge the battery or provide power. Regenerative Braking: Integral part of the transmission's operation, capturing energy during deceleration. 📐 Dimensions Exterior Length: 177.1 inches (4498 mm) Width: 70.7 inches (1796 mm) Height: 57.1 inches (1450 mm) Wheelbase: 106.5 inches (2705 mm) Interior Passenger Volume: 82.1 cu ft (2.32 m³) Cargo Cargo Volume Rear Seats Up: 10.6 cu ft (0.30 m³) Cargo Volume Rear Seats Down: 19.4 cu ft (0.55 m³) Weights Curb Weight: 3775 lbs (1712 kg) Gross Vehicle Weight Rating: 4695 lbs (2130 kg) 🛡️ Safety Features Ratings NHTSA...
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Sku: 76823
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Chevrolet Chevy Volt Electric Car Complete Workshop Service Repair Manual 2012 2013Chevrolet Chevy Volt Electric Car Complete Workshop Service Repair Manual 2012 2013Chevrolet Chevy Volt Electric Car Complete Workshop Service Repair Manual 2012 2013Chevrolet Chevy Volt Electric Car Complete Workshop Service Repair Manual 2012 2013
The Chevrolet Volt, first generation, produced for the 2012 and 2013 model years, represents a pioneering step in extended range electric vehicle (EREV) technology. This compact hatchback, designed with an aerodynamic philosophy, offers a unique selling proposition by combining electric-only driving for daily commutes with a gasoline engine to extend its operational range, effectively addressing range anxiety. Its innovative Voltec powertrain system, featuring a battery pack, electric motors, and a 1.4L Ecotec gasoline range extender, delivers a blend of efficiency and practicality. Known for its advanced electrification strategy and robust engineering, the Volt stands as a significant marker in the evolution of sustainable automotive solutions, making it a noteworthy vehicle for environmentally conscious drivers. This comprehensive workshop service repair manual provides extensive guidance for the Chevrolet Volt (PHEV1 chassis code) covering the 2012 and 2013 model years. It details maintenance procedures, diagnostic and troubleshooting steps, component removal and installation, and repair and overhaul instructions for all major systems, including the Electric Drive Unit (EDU), battery pack, range extender engine, chassis, suspension, and electrical systems. With over 2000 pages of information in English, this manual is an indispensable resource for owners, mechanics, and technicians seeking to maintain, diagnose, and repair the vehicle, ensuring its optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Chevrolet
Model:
Volt
Generation:
First Generation
Model Years Covered:
2012, 2013
Codes
Chassis Code:
PHEV1
👋 Introduction
Market Position
Vehicle Segment:
Compact Hatchback / Extended Range Electric Vehicle (EREV)
Unique Selling Proposition:
Pioneering EREV technology, offering electric-only driving for daily commutes with a gasoline engine for extended range.
Competitive Analysis
Key Competitors:
Nissan Leaf (BEV), Toyota Prius Plug-in Hybrid
Key Features
Electrification Strategy:
Voltec powertrain system featuring a battery pack, electric motors, and a small gasoline engine as a generator.
Design Philosophy:
Aerodynamic design for improved efficiency, innovative powertrain integration.
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete Workshop Service Repair Manual
Page Count
Estimated Pages:
Over 2000 (typical for comprehensive service manuals of this era)
Manual Type
Manual Category:
Workshop Service Repair Manual
Language
Primary Language:
English
Format
File Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Electric Drive Unit (EDU), Extended Range Electric Motor, Regenerative Braking System, Battery Pack (Volt's Voltec System)
Engine And Fuel:
1.4L Ecotec Gasoline Range Extender Engine (LLT), Fuel Tank and Lines, Exhaust System
Transmission:
Electric Drive Unit (eCVT-like functionality), Power Split Device
Chassis And Suspension:
Front and Rear Suspension, Steering System, Brakes (including regenerative braking integration)
Electrical And Electronics:
High Voltage Battery Management System (BMS), Powertrain Control Module (PCM), Body Control Module (BCM), Infotainment System, Lighting, Wiring Diagrams, Fuses, Relays
Body And Interior:
Body Panels, Doors, Seats, HVAC System, Interior Trim, Safety Restraints (Airbags)
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Tire Rotation, Battery Coolant Service
Diagnostics And Troubleshooting:
Fault Code Diagnosis, Symptom-Based Troubleshooting, Electrical System Diagnostics, Powertrain Diagnostics
Repair And Overhaul:
Engine Overhaul, Transmission (EDU) Repair, Suspension Component Replacement, Brake System Repair, Electrical Component Replacement, Battery Pack Servicing (limited to module replacement/testing where applicable)
Component Removal And Installation:
Detailed instructions for replacing virtually all major and minor components
Technical Depth
Depth Of Information:
Comprehensive, covering everything from basic fluid checks to complex electrical system diagnostics and powertrain component rebuilds.
Diagnostic Tools:
Information on diagnostic trouble codes (DTCs), scan tool usage, and specialized procedures may be included.
📊 Manual Specifications
File Format
PDF Quality:
Typically high-resolution scans of original factory manuals, optimized for readability and searchability.
Print Quality
Printable:
Yes, the PDF format is generally designed to be printable.
Binding Type
Binding Method:
N/A (Digital PDF)
Paper Type
Paper Quality:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Range Extender Engine (Gasoline)
Engine Code:
LLT (GM Ecotec family)
Displacement:
1.4 Liters (1398 cc)
Cylinders:
4
Configuration:
Inline
Valvetrain:
DOHC, 16 Valves
Performance
Gasoline Engine Horsepower:
84 hp @ 4800 rpm
Gasoline Engine Torque:
96 lb-ft @ 3800 rpm
Electric Motor Peak Horsepower:
149 hp
Electric Motor Peak Torque:
273 lb-ft
Fuel System
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
9.3 gallons (35.2 L)
Ignition System:
Electronic Ignition
🔧 Transmission
Standard
Transmission Type:
Electric Drive Unit (EDU) with Power Split Device
Optional
Optional Transmission:
N/A
Features
Drive Modes:
Hold, Sport, Normal, Mountain
Power Delivery:
Electric motors drive the wheels directly; gasoline engine acts as a generator to recharge the battery or provide power.
Regenerative Braking:
Integral part of the transmission's operation, capturing energy during deceleration.
📐 Dimensions
Exterior
Length:
177.1 inches (4498 mm)
Width:
70.7 inches (1796 mm)
Height:
57.1 inches (1450 mm)
Wheelbase:
106.5 inches (2705 mm)
Interior
Passenger Volume:
82.1 cu ft (2.32 m³)
Cargo
Cargo Volume Rear Seats Up:
10.6 cu ft (0.30 m³)
Cargo Volume Rear Seats Down:
19.4 cu ft (0.55 m³)
Weights
Curb Weight:
3775 lbs (1712 kg)
Gross Vehicle Weight Rating:
4695 lbs (2130 kg)
🛡️ Safety Features
Ratings
NHTSA Front Crash Rating:
5-Star (Overall)
IIHS Side Impact Rating:
Good
Active Features
ABS:
Yes
Traction Control:
Yes
Electronic Stability Control:
Yes (StabiliTrak)
Passive Features
Airbags Front:
Driver and Passenger Frontal, Knee
Airbags Side:
Front and Rear Side-Curtain, Front Seat-Mounted Side
Seatbelts:
3-point front and rear with pretensioners
💡 Technology Features
Infotainment
Infotainment System:
Chevrolet MyLink with touchscreen interface
Audio System:
AM/FM stereo with CD player, MP3 playback, USB port, auxiliary input.
Driver Assistance
Rearview Camera:
Standard on most trims
Parking Sensors:
Optional
Connectivity
Bluetooth:
Standard for hands-free calling and audio streaming
Charging Port:
Standard J1772 charging port for Level 1 and Level 2 charging
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 7,500 miles (12,070 km) or 12 months, whichever comes first. Use synthetic oil.
Engine Air Filter Replacement:
Approximately every 30,000-50,000 miles (48,000-80,000 km), or as per manual inspection.
Cabin Air Filter Replacement:
Every 20,000-30,000 miles (32,000-48,000 km) or annually.
Brake Fluid Change:
Inspect every 30,000 miles (48,000 km), replace as needed based on condition.
Battery Coolant Replacement:
Initial change at 150,000 miles (241,400 km), then every 50,000 miles (80,000 km) or 5 years thereafter.
Fluid Specifications
Engine Oil Type:
SAE 0W-30 Full Synthetic (API SN, ILSAC GF-5)
Engine Oil Capacity:
4.0 quarts (3.8 L) with filter
Battery Coolant Type:
Dex-Cool (GM P/N 19372363 or equivalent purple coolant)
Transmission Fluid Type:
Dexron VI (for planetary gearset lubrication within EDU)
Known Issues
Common Wear Items:
Brake pads (due to regenerative braking, wear can be less than expected but should be monitored), 12V battery, tires.
Powertrain Concerns:
Occasional issues with battery cooling systems, charging port components, and software glitches related to powertrain management.
Range Extender Engine Concerns:
Potential for oil consumption in high-mileage engines, ignition coil issues.
📚 Vehicle History
Brand Heritage
Manufacturer History:
Chevrolet, a division of General Motors, has a long history of automotive innovation and manufacturing.
Model Evolution
Volt Introduction:
The Chevrolet Volt was introduced as a groundbreaking EREV, aiming to address range anxiety associated with pure EVs.
First Generation Timeline:
Launched for the 2010 model year in the US, with significant updates for the 2012 and 2013 model years.
Production
Manufacturing Location:
Detroit-Hamtramck Assembly Plant, Michigan, USA
🏆 Awards & Recognition
Recognitions
Green Car Of The Year:
Awarded Green Car of the Year by Green Car Journal (2011 model year, influencing perception of later models)
Ratings
Epa Electric Range:
Approximately 38 miles (61 km) for 2013 model
Epa Mpge:
101 MPGe combined (electric), 37 MPG combined (gasoline)
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